Systems and processes for processing hydrogen and carbon monoxide

ABSTRACT

In various implementations, various feed gas streams which include hydrogen and carbon monoxide may be processed for conversion to product streams. For example, the feed gas stream may be processed using the Fischer-Tropsch process. Unconverted hydrogen and carbon monoxide can be recycled using an off-gas catalytic reformer and a gas turbine exhaust gas heat exchanger that will perform preheating duties.

CLAIM OF PRIORITY

This application is a continuation of and claims priority under 35 USC§119(e) to U.S. patent application Ser. No. 12/488,377, filed on Jun.19, 2009, the entire contents of which are hereby incorporated byreference, which claims priority under 35 USC §119(e) to U.S.Provisional Application No. 61/074,571, filed Jun. 20, 2008, the entiredisclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to hydrogen and carbon monoxideprocessing.

BACKGROUND

Hydrocarbon and carbonaceous feedstock can be converted into H₂ and COsynthesis gas mixtures with varying ratios of H₂ to CO. Feedstock mayinclude coals, natural gas, oil fractions, bitumen and tar-like refinerywastes, pet-coke and various forms of biomass. The synthesis gasmixtures can be converted into valuable hydrocarbons and chemicals usingcatalytic processes.

SUMMARY

In various implementations, unconverted synthesis gas, bi-product gasesand inert gases left after catalytic conversion of synthesis gas intohigher value hydrocarbon products and chemicals are converted intoadditional quantities of synthesis gas to improve the economics of theoverall processes.

The conversion processes used to produce the synthesis gas may includepartial oxidation, steam reforming, auto-thermal reforming, convectivereforming, carbon monoxide shift conversion, and combinations of theseprocesses. In some implementations, processes similar to the processesdescribed in U.S. Pat. Nos. 6,669,744 and 6,534,551 may be used toproduce H₂ and CO synthesis gas mixtures with extremely high efficiency.This defines a process for the production of synthesis gas from ahydrocarbon fuel and steam and oxygen gas wherein at least part of anysteam requirement is provided by heat exchange against an exhaust gasfrom a gas turbine driving an air compressor in an air separation unitsupplying at least part of the oxygen requirement for the synthesis gasgeneration process. An important feature of this process is theintegration of a primary synthesis gas production unit, such as apartial oxidation reactor (POX) or an auto-thermal reactor (ATR) with aconvectively heated steam/hydrocarbon catalytic reformer (GHR), so thatthe combined synthesis gas product stream can be used to provide theheat required for the endothermic steam/hydrocarbon reforming reactionstaking place in the GHR tubes. The combination maximizes the synthesisgas production from a given quantity of hydrocarbon feed and provides avery compact and low cost synthesis gas generation process byeliminating the normal large quantity of high pressure steam productiongenerally used for power production in steam turbines and substitutingmuch cheaper high efficiency gas turbines thermally linked to thesynthesis gas generation process.

Examples of the products of catalytic conversion of synthesis gasinclude Fischer-Tropsch hydrocarbons, methanol, oxo-alcohols, andmethane. In some implementations, these catalytic processes may notresult in complete conversion of the feed synthesis gas into the desiredproducts. Since there will be some unconverted synthesis gas, theunconverted synthesis gas may be recycled back to the inlet of thecatalytic conversion process. The unconverted synthesis gas may be amixed stream, often including other compounds such as inert gases (e.g.,argon and nitrogen) and carbon dioxide. These other compounds may ariseeither from mixture with oxygen used in partial oxidation or autothermal reforming to produce the synthesis gas or the carbonaceous orhydrocarbon feedstock used. In addition, side reactions in the catalyticsynthesis gas conversion processes may produce bi-products such as CH₄,CO₂ and possibly C₃ and C₄ components that may be in the mixed streamwith the unconverted synthesis gas.

To improve the process economics (e.g., by maximizing conversionefficiency of feedstocks to final products), one, more, or none of thefollowing features may be implemented. The unconverted synthesis gas maybe used with the associated inert components and other bi-products, andmay be recycled back to the feed point of the synthesis gas conversionprocess.

In some implementations, the unconverted gas recycle system may be usedwith various synthesis gas generation processes, as described below oras described in U.S. Pat. Nos. 6,669,744 and 6,534,551. As described inU.S. Pat. Nos. 6,669,744 and 6,534,551, at least part of any steamrequirement for a process for the production of synthesis gas isprovided by heat exchange with exhaust gas from a gas turbine driving anair separation unit, which supplies at least part of any oxygenrequirement for the synthesis gas production. The described processesmay be used when the synthesis gas is used in methanol syntheses orFischer-Tropsch processes.

In some implementations, carbon dioxide and other inert gases, such asargon and nitrogen, may be separated from the unconverted synthesis gasto reduce the effect on the synthesis gas conversion process and/or toprevent a build-up of inert gas concentration in the catalyticconversion process. Buildup of inert gases in the catalytic conversionprocess may affect the equilibrium of the reactions and, thus, reduceconversion rates. In some implementations, by using the finalunconverted synthesis gas, inert gases and by-products and steam as feedto a catalytic reformer process (e.g., off-gas catalyticsteam/hydrocarbon reformer), more synthesis gas may be produced for thesynthesis gas conversion process. Part of the off gas containing inertsmay be used as combustion fuel gas to heat the catalytic reformer andthis will limit the buildup of inerts in the system.

In some implementations, the system may include an off-gas catalyticreformer integrated with a gas turbine exhaust gas heat exchanger. Useof the off-gas catalytic reformer integrated with a gas turbine exhaustgas heat exchanger may reduce the need for and/or eliminate the entirereformer furnace exhaust gas convective heat exchange system, which isan integral part of typical conventional catalytic steam/hydrocarbonreforming processes that produce H₂+CO synthesis gas. This may beimplemented by ducting a portion of or the entire reformer furnaceexhaust gas into the base of the gas turbine exhaust gas fired heatexchanger. In some implementations, the ducting may be at or proximate apoint above the burner section. Use of the integrated off-gas catalyticreformer with a gas turbine exhaust gas heat exchanger may allow thepreheating duties (e.g., for the entire system) to be performed in thisone unit.

In some implementations, part of the exhaust gas from the gas turbinemay be used as combustion air for the off-gas catalytic reformer furnaceburners. The exhaust gas may be approximately 400° C. to 500° C. and itmay require compression to a pressure suitable for the burners in thecatalytic reformer furnace. Use of at least a portion of the exhaust gasas combustion air may reduce the quantity of fuel needed for heating thereformer furnace. Reducing the amount of fuel needed for heating mayreduce processing costs. Alternatively, the combustion air may be takenfrom a suitable interstage position in the O₂ plant air compressor.

In some implementations, the entire product synthesis gas cooling trainassociated with the off-gas catalytic reformer, normally associated witha steam/hydrocarbon catalytic reformer, may be removed (e.g., the needfor the product synthesis gas cooling train may be removed) oreliminated from the system. Instead, the synthesis gas leaving the tubesat the outlet of the reformer furnace may be fed into the inlet of thewaste heat boiler, which takes the entire synthesis gas stream leavingthe GHR shell side. This may eliminate or reduce the need for a secondwaste heat boiler, feed-water pre-heater, water cooled synthesis-gascooler, water separator and/or a separate steam system. Eliminatingthese components may reduce processing costs (e.g., by utilizing heatgeneration within the process) and/or reduce system costs (e.g., byreducing the cost of components needed for the system and/or by removingmaintenance costs associated with the eliminated components).

These features may reduce the capital cost and/or maximize theefficiency of the additional off-gas catalytic reformer. These featuresmay be used in combination with the basic technology disclosed in U.S.Pat. Nos. 6,669,744 and 6,534,551, which integrate synthesis gasgeneration with a gas turbine power unit with waste heat recovery.

In some implementations, H₂ and CO production from the combined primarysynthesis gas generation reactor, POX or ATR may be increased and/ormaximized. The primary synthesis gas generation reactor may beintegrated with the GHR. H₂ and CO production may be increased byrecycling separated CO₂ from the total synthesis gas production to theprimary synthesis gas generation reactor and/or the GHR feed gas streamsgiving a higher CO to H₂ ratio in the primary synthesis gas, and bybalancing this with the higher H₂ to CO ratio from the off-gas catalyticreformer to increase the production of H₂ and CO from the totalsynthesis gas generation system and achieve the required H₂ to CO ratioin the synthesis gas feed to the catalytic synthesis gas conversionprocess. In some implementations, a CO₂ separation unit may be used. TheCO₂ separation unit may be at least partially based on solvent scrubbingof the combined synthesis gas feed streams entering the catalyticconversion of synthesis gas process. This separated CO₂ may be recycled(e.g., up to 100% recycle) back to the primary synthesis gas generationreactor and/or the GHR.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features,objects, and advantages of the implementations will be apparent from thedescription and drawings.

DESCRIPTION OF DRAWINGS

FIG. 1 illustrates an example processing system.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

In various implementations, various feed gas streams which includehydrogen and carbon monoxide, may be processed for catalytic conversionto product streams. As an example, the feed gas stream may be processedusing the Fischer-Tropsch process. Unconverted hydrogen and carbonmonoxide, together with other components such as inerts, hydrocarbonsand CO₂, can be recycled by conversion primarily to H₂+CO using anoff-gas catalytic steam/hydrocarbon reformer, and a gas turbine exhaustgas heat exchanger may perform preheating duties. By utilizing heatgenerated during the process to preheat various portions, costs may bereduced.

FIG. 1 illustrates an example processing system for the processing of H₂and CO. As illustrated, an autothermal reforming reactor (ATR) (unit 1)produces a product stream that includes a CO and H₂ mixture (stream 2)plus unconverted CH₄, steam and CO₂. As an example, the product stream(stream 2) may be at approximately 37 bar and approximately 1025° C. O₂is fed to the ATR (unit 1) at approximately 270° (stream 3). The O₂ maybe produced in an air separation unit (ASU) (unit 7). A mixture ofnatural gas and steam (e.g., at approximately 550° C.) (stream 4) mayalso be fed to the burner (unit 5) of the ATR (unit 1). The mixture ofnatural gas and steam (stream 4) may be a portion of a product streamfrom a first heater (unit 31). The ATR (unit 1) may also include acatalyst bed (unit 6) for reforming the gas mixture produced in theburner (unit 5).

The Gas Heated Reformer (GHR) (unit 8) may also be fed with a mixture ofnatural gas and steam (e.g., at approximately 550° C.) (stream 36). Themixture of natural gas and steam may flow downwards through catalyst inthe GHR (e.g., catalyst filled vertical open ended tubes) (unit 8) andmay exit the GHR mainly as a mixture of H₂ and CO with some unconvertedCH₄, CO₂, steam and inerts. This gas may exit at approximately 900° C.This gas may also mix with the product gas of the ATR (stream 2) in theGHR (unit 8). The combined stream (e.g., gas exiting the catalyst tubesmixed with the product stream from the ATR) flows upwards through theshell side of the GHR (unit 8) and/or may provide the heat required forthe steam/hydrocarbon reforming reactions. The product gas stream(stream 9) may exit the GHR at approximately 600° C. and approximately36 bar. Other arrangements, such as POX+GHR, are also possible.

A Fischer-Tropsch multistage reactor with associated hydro-treater (FT)(unit 10) may process a H₂ and CO feed stream (stream 16) to produce oil(stream 11), liquefied petroleum gas (LPG) (stream 12) and water (stream13). The H₂ and CO feed stream may be at approximately at 35 bar and 30°C. The unconverted gas mixture (stream 14) produced by the FT reactorafter product separation may include H₂, CO, CH₄, inert gases such as N₂and Ar, and trace quantities of C₂, C₃ and C₄. The unconverted gasmixture (stream 14) may be at approximately 30 bar. The compounds in theunconverted gas mixture may include components from the oxygen (stream3) and the natural gas feed (stream 15). The unconverted gas stream(stream 14) or “off-gas” generally contains approximately 5% to 10% ofthe H₂ and CO present in the feed stream 16 to the FT reactor (unit 10).

Stream 14 may be converted to H₂ and CO synthesis gas in thesteam/hydrocarbon off-gas catalytic reformer 17. The unconverted gasstream 14 is divided (e.g., after exiting the FT reactor) into at leasttwo streams, stream 18 and stream 20. In some implementations, stream 14may be divided unequally into the at least two streams (e.g., stream 20may be larger, by volume or weight, than stream 18). The pressure ofstream 18 is reduced to approximately 1.3 bar in valve 19 (e.g., thevalve allows the stream to be expanded) to produce stream 18′. Stream18′, which includes part of the unconverted gas mixture at a lowerpressure than the exit stream from the FT reactor, is used as fuel gasfor heating the furnace of the steam/hydrocarbon off-gas reformer (unit17). Thus, separate or additional fuel may not be necessary to operatethe reformer (unit 17), which may reduce costs.

Stream 20 may be compressed to approximately 38 bar in compressor 21 toproduce stream 52. Stream 52 may be provided as a portion of the feed toheater 31. The feed stream (stream 51) to the steam/hydrocarbon off-gascatalytic reformer (unit 17) may be produced in the heater 31 by heatingstream 52 in the heater 31; mixing steam, as required for the reformer,from stream 50; and superheating the mixture. Stream 51, which isprovided as feed to the steam/hydrocarbon off-gas catalytic reformer(unit 17), may be at approximately 550° C.

A gas turbine (unit 22) drives an air compressor (unit 23) which mayprovide the feed air stream 24 to the ASU (unit 7). A portion of thenatural gas feedstock (stream 15) may be provided to the gas turbine(unit 22) as fuel (stream 32). The gas turbine exhaust (stream 25) maybe at approximately 450° C. The gas turbine exhaust (stream 25) may bedivided into at least two streams, stream 26 and stream 29, for example,as it exits the gas turbine (unit 22). Stream 26 may be compressed(e.g., to approximately 1.2 bar). The stream 26 may be compressed using,for example, a blower (unit 27). The stream exiting the blower isprovided as the combustion air stream (stream 28) for the furnace of thesteam/hydrocarbon off-gas catalytic reformer (unit 17). Alternatively,stream 26 may be taken from an intermediate pressure interstate positionof the ASU feed air compressor (unit 23)

Stream 29 is further heated by the combustion of the natural gas stream30 to produce heating gas for the heater (unit 31). The heater (unit 31)may be able to perform the preheating duties for all the natural gas andsteam requirements of the whole system. In some implementations, theheater may perform a portion (e.g., a majority) of the preheatingduties. For example, the natural gas stream (stream 30) may be a portionof the natural gas feed stock (stream 15).

The exit combustion product stream (stream 33) from the furnace of theoff-gas catalytic reformer (unit 17) may be at approximately 700° C. to1100° C. and/or may enter proximate the base of the heater (unit 31).The exit stream (stream 33) may mix with the hot gas exiting the burnerarea of the heater (unit 31) and be cooled (e.g., the mixed stream mayhave an exit temperature of approximately 200° C.). In someimplementations, the exit stream may be cooled because of the heatingduty of the stream. The resulting cooled gas stream (stream 34) may thenexit the heater and may be vented to the atmosphere using, for example,an induced draft fan (unit 35). The induced draft fan (unit 35) mayensure that the exhaust gas pressure of the gas turbine stream (stream25) is adequate for power generation in the gas turbine (unit 22).

The H₂ and CO synthesis gas (stream 37) produced in the off-gascatalytic reformer (unit 17) may exit at a temperature fromapproximately 750° C. to 900° C. and may be mixed with the synthesis gasproduct stream (stream 9) exiting the shell side of the GHR (unit 8).The combined synthesis gas stream may cool in the waste heat boiler(unit 38) and the feed water heater (unit 39). At least a portion ofthis combined synthesis gas stream may then be fed into a water cooler(unit 40). The exit stream from the water cooler (unit 40) may then befed into a water separator (unit 41), which removes at least a portionof the condensed water from the combined synthesis gas stream. CO₂ maybe removed from the cooled synthesis gas stream 42 using, for example, asolvent scrubber (unit 43). Regeneration heat for the solvent CO₂scrubber (unit 43) is provided by the low pressure steam generated as aby-product in the FT reactor (unit 10). The separated CO₂ (stream 44)may be compressed (e.g., to approximately 38 bar) in a compressor (unit45) to produce a CO₂ stream (stream 46). At least a portion of theproduced stream of CO₂ may then be mixed with the desulphurised naturalgas feed stream (stream 47) to the heater (unit 31) to provide the feedstream (stream 49) for the GHR (unit 8). The ATR desulphurised naturalgas feed stream (stream 48) and the mixed GHR feed stream (stream 49)may pass through a first stage of heating in the heater (unit 31). Thestreams (streams 48, 49) are then mixed with steam, as required for theprocess, from stream 50. The steam may be saturated steam atapproximately 38 bar which was produced in the waste heat boiler (unit38). The combined streams are then further heated to an exit temperatureof approximately 550° C. in the heater (unit 31) to produce exit streams(streams 4 and 36).

An effect of the process integration may be to allow the FT off-gas,which has a very large amount of CH₄ content, to be used to produce upto about 25% of the total H₂ and CO required by the FT process. This maybe performed in a way that increases or maximizes efficiency. The ratioof CO to H₂ in the combined feed stream (stream 16) entering the FTreactor system (unit 10) can be adjusted by varying the quantity of CO₂(stream 46) fed to the GHR (unit 8) to produce a high CO to H₂ ratio instream 9 compensated by a low CO to H₂ ratio in stream 37. Thismaximizes the quantity of by-product CO₂ recycled for use in the processand minimizes CO₂ emission to atmosphere. In addition, the peripheralequipment required by a conventional steam/hydrocarbon reformer may besubstantially eliminated or reduced. This may be performed at very lowcapital cost increment. The inert gases (e.g., N₂, Ar, CO₂) in stream 18may be vented to atmosphere through heater 31. This may inhibit theconcentration of inert gases from building up, which may be causedotherwise when synthesis gas is recycled through the system. When theconcentration of inert gases increases beyond a specified concentration,the process efficiency may be decreased.

Although a specific implementation of the system is described above,various components may be added, deleted, and/or modified. In addition,the various temperatures and/or concentrations are described forexemplary purposes. Temperatures and/or concentrations may vary asappropriate. In addition, although the above process is described interms of an FT process, similar systems may be used in conjunction withmethanol synthesis.

A number of implementations have been described. Nevertheless, it willbe understood that various modifications may be made without departingfrom the spirit and scope of the implementations. Accordingly, otherimplementations are within the scope of this application.

It is to be understood the implementations are not limited to particularsystems or processes described which may, of course, vary. It is also tobe understood that the terminology used herein is for the purpose ofdescribing particular implementations only, and is not intended to belimiting. As used in this specification, the singular forms “a”, “an”and “the” include plural referents unless the content clearly indicatesotherwise. Thus, for example, reference to “a reactor” includes acombination of two or more reactors and reference to “a feedstock”includes different types of feedstocks.

What is claimed is:
 1. A process for producing higher molecular weighthydrocarbon compounds and/or oxygenates from a hydrocarbon gascomprising methane, said process comprising: generating an initialsynthesis gas (“syngas”) stream comprising carbon monoxide and hydrogenin a two-stage process by reaction of hydrocarbon gas comprisingmethane, steam and oxygen; generating oxygen in an air separation planthaving an air compressor driven by a gas turbine. combusting a fuel gasin exhaust from the gas turbine in a fired heater to provide at least aportion of a heat duty for preheating feed streams to synthesis gasproduction units; catalytically converting synthesis gas to at least oneof hydrocarbons or oxygenates in a process unit, at least a portion ofthe initial syngas stream is provided as feed gas to the process unit;separating off-gas from the syngas conversion process, the off-gasincluding unreacted syngas from the syngas feed stream, inerts, reactionproducts, CO₂ and water vapour; generating additional synthesis gas in acatalytic steam/hydrocarbon reformer using the off-gas, a first part ofthe off-gas is used to provide at least a portion of the fuel gas forthe reformer heating, and a second portion is used to provide at least aportion of the feed to the catalytic reformer mixed with steam;combining the additional syngas with the initial syngas to form a feedfor the syngas catalytic conversion process; adding the combustion gasexiting the off-gas catalytic reformer furnace to the hot combustion gasused for process heating in the gas turbine exhaust fired heater; andadding the reformed synthesis gas stream leaving the off-gas catalyticreformer furnace to the initial syngas stream up-stream of a waste heatboiler producing high pressure steam for synthesis gas generation. 2.The method of claim 1 further comprising using at least a portion of thehot exhaust from the gas turbine compressed as combustion air for theoff-gas catalytic reformer furnace burners
 3. The method of claim 1further comprising using at least a portion of air taken from the airseparation unit air compressor at a suitable interstage point before theintercooler having the required pressure for the burners as combustionair for the off-gas catalytic reformer furnace.
 4. The method of claim1, wherein generating the initial syngas stream comprises: reactinghydrocarbon-containing fuel with an oxidant gas comprising molecularoxygen and steam in a first autothermal catalytic reformer to produce asyngas product; and endothermically reforming hydrocarbon-containingfuel gas with steam over a catalyst in a heat exchange reformer toproduce a heat exchange-reformed syngas product, wherein at least aportion of the heat used in the generation of said heatexchange-reformed syngas product is obtained by recovering heat from thesyngas product leaving the autothermal catalytic reformer.
 5. The methodof claim 1, wherein generating the initial syngas stream comprises:exothermically reacting hydrocarbon-containing fuel with an oxidant gascomprising molecular oxygen in a first reactor to produce anexothermically-generated syngas product; and endothermically reforminghydrocarbon-containing fuel gas with steam over a catalyst in a heatexchange reformer to produce a heat exchange-reformed syngas product,wherein at least a portion of the heat used in the generation of saidheat exchange-reformed syngas product is obtained by recovering heatfrom the exothermically-generated syngas product.
 6. The method of claim1, the syngas conversion process comprises a Fischer-Tropsch system. 7.The method of claim 1, the syngas conversion process comprises amethanol system.
 8. The method of claim 1, further comprising separatingCO₂ from the feed gas stream entering the syngas conversion process andrecycling at least a portion of the compressed CO₂ to the initial syngasgeneration system to form an initial syngas having a CO to H₂ ratiohigher than that required by the catalytic syngas conversion process andsimultaneously operating the off-gas reformer to produce a syngasproduct having a low CO to H₂ ratio such that the mixed streams have therequired CO to H₂ ratio for the catalytic syngas conversion process andthe quantity of CO₂ recycled is maximized.
 9. The method of claim 1,further comprising adding additional fresh hydrocarbon feed to theoff-gas catalytic reformer to allow additional H₂ production to ensureall the available CO₂ separated from the feed syngas to the syngascatalytic conversion process is recycled to the initial syngasproduction system.
 10. A system for producing higher molecular weighthydrocarbon compounds and/or oxygenates from a hydrocarbon gascomprising methane, said system comprising: synthesis gas productionunits that generate an initial synthesis gas (“syngas”) stream in a twostage process comprising carbon monoxide and hydrogen by reaction ofhydrocarbon gas comprising methane with steam and oxygen; an airseparation plant that generates oxygen having an air compressor drivenby a gas turbine; a fired heater that combusts exhaust from the gasturbine to provide at least a portion of the heat duty for preheatingfeed streams to the synthesis gas production units; a process unit thatcatalytically converts synthesis gas to at least one of hydrocarbons oroxygenates and separates off-gas from synthesis gas, at least a portionof the initial syngas stream is provided as feed gas, the off-gasincluding unreacted syngas from the syngas feed stream, inerts, reactionproducts, CO₂ and water vapour; an off-gas catalytic steam/hydrocarbonreformer that generates additional synthesis gas using the off-gas, afirst part of the off-gas is used to provide at least a portion of thefuel gas for the reformer heating, and a second portion is used toprovide at least a portion of the feed to the catalytic reformer mixedwith steam; a first outlet that combines the additional syngas with theinitial syngas to form a feed for the syngas catalytic conversionprocess; a second outlet that adds the combustion gas exiting theoff-gas catalytic reformer furnace to the hot combustion gas used forprocess heating in the gas turbine exhaust fired heater; and a thirdoutlet that adds the reformed synthesis gas stream leaving the off-gascatalytic reformer furnace to the initial syngas stream up-stream of awaste heat boiler producing high pressure steam for synthesis gasgeneration.
 11. The system of claim 10 further comprising using at leasta portion of the hot exhaust from the gas turbine compressed ascombustion air for the off-gas catalytic reformer furnace burners. 12.The system of claim 10 further comprising using at least a portion ofair taken from the air separation unit air compressor at a suitableinterstage point before the intercooler having the required pressure forthe burners as combustion air for the off-gas catalytic reformerfurnace.
 13. The system of claim 10, wherein the synthesis gasproduction units comprise: autothermal reforming reactor thatexothermically reacts hydrocarbon-containing fuel with an oxidant gascomprising molecular oxygen in a first reactor to produce anexothermically-generated syngas product; and a gas-heated reformer thatendothermically reforms hydrocarbon-containing fuel gas with steam overa catalyst in a heat exchange reformer to produce a heatexchange-reformed syngas product, wherein at least a portion of the heatused in the generation of said heat exchange-reformed syngas product isobtained by recovering heat from the exothermically-generated syngasproduct.
 14. The system of claim 10, wherein generating the initialsyngas stream comprises: partial oxidation reactor that exothermicallyreacts hydrocarbon-containing fuel with an oxidant gas comprisingmolecular oxygen in a first reactor to produce anexothermically-generated syngas product; and a gas heated reformer thatendothermically reforms hydrocarbon-containing fuel gas with steam overa catalyst in a heat exchange reformer to produce a heatexchange-reformed syngas product, wherein at least a portion of the heatused in the generation of said heat exchange-reformed syngas product isobtained by recovering heat from the exothermically-generated syngasproduct.
 15. The system of claim 10, the syngas conversion process unitcomprises a Fischer-Tropsch system.
 16. The system of claim 10, thesyngas conversion process comprises a methanol system.
 17. The system ofclaim 10, further comprising a filter that separates CO₂ from the feedgas stream entering the syngas conversion process and recycling at leasta portion of the compressed CO₂ to the initial syngas generation systemto form an initial syngas having a CO to H₂ ratio higher than thatrequired by the catalytic syngas conversion process and simultaneouslyoperating the off-gas reformer to produce a syngas product having a lowCO to H₂ ratio such that the mixed streams have the required CO to H₂ratio for the catalytic syngas conversion process and the quantity ofCO₂ recycled is maximized.
 18. The system of claim 10, furthercomprising a hydrocarbon inlet that adds additional fresh hydrocarbonfeed to the off-gas catalytic reformer to allow additional H₂ productionto ensure all the available CO₂ separated from the feed syngas to thesyngas catalytic conversion process is recycled to the initial syngasproduction system.